eCommerce businesses face an overwhelming array of box size options, even when working with just the three major carriers: USPS, UPS, and FedEx. Together, these carriers offer a wider range of sizes than most businesses could ever need. While having plenty of choices is helpful, dealing with standard shipping box sizes can also be a daunting task.
To minimize fulfillment costs and make smarter decisions, businesses need a clear understanding of their options. In this article, we’ll break down how to select the right carrier and box size to help you save on shipping expenses.
- How does box size relate to shipping costs
- Box size options for the major mail carriers
- How a 3PL can help with fulfillment costs
In this post, we will explain the concept of box size and its relationship to shipping costs.
Box Size and Shipping Calculations
Shipping carriers determine their charges based on both the weight and size of the packages they transport. Each carrier and size category has specific weight limits that influence shipping costs.
However, it’s crucial to understand that carriers use two types of weight to calculate your shipping charges: actual weight and dimensional (DIM) weight. The actual weight is simply the physical weight of your product in pounds, which many businesses focus on when trying to reduce costs. But here’s the catch: if the DIM weight is greater than the actual weight, carriers will use the DIM weight to calculate your charges.
DIM weight factors in the package’s dimensions to estimate shipping costs. This approach is significant for items that are lightweight but bulky, such as curtains, bathroom rugs, or large display pieces that can’t be packed into smaller boxes. Since larger packages occupy more space in delivery trucks, carriers account for box size to ensure the efficient use of their resources, which directly impacts the price you pay.
Understanding how DIM weight works can help your business optimize shipping strategies and reduce unnecessary costs. Always consider both actual and dimensional weight when planning your packaging to avoid unexpected shipping fees.
Box Size Options from the Major Carriers
Every primary carrier offers a range of box options, each tailored to meet different shipping needs. To help you make the best choice, we’ve compared the rates and features of their most popular boxes, allowing you to select the ideal option for your delivery requirements.
USPS
USPS provides a variety of shipping solutions, but their flat-rate boxes are particularly beneficial for eCommerce businesses shipping multiple small items. They offer free shipping supplies and priority mail services, leveraging the post office’s fulfillment system to deliver local packages more affordably than many major carriers.
Here’s a selection of USPS box sizes options, including both Priority Mail and Flat Rate choices:
| Box Type | Price | Maximum weight | Maximum dimensions |
| Priority Mail Express flat rate envelope | $27.10 Post Office
$23.50 Commercial Base |
70 lbs. | 108” |
| Priority Mail flat rate | $7.95 Post Office
$7.41 Commercial Base |
70 lbs. | 108” |
| Priority Mail Regional Rate Boxes | $8.08 Post Office | 70 lbs. | 108” |
| First-Class Mail | $0.58 (letters)
$0.88 (oversized letters) $1.16 (large envelopes) $4.30 (small packages) |
3.5 oz (letters)
13oz (parcels) |
N/A |
| First-Class Package Service | $3.31 Commercial
$4.30 Retail |
70 lbs. | 22”x18” x 15” |
| Flat Rate Envelope | $8.70 | 70 lbs. | 12 ½” x 9 ½” |
| Padded Flat Rate Envelope | $9.30 | 70 lbs. | 12 ½” x 9 ½” |
| Small Flat Rate Box | $9.20 | 70 lbs. | 8 11⁄16″ x 5 7⁄16″ x 1 3⁄4″ |
| Medium Flat Rate Box | $16.25 | 70 lbs. | 11 1⁄4″ x 8 3⁄4″ x 6″
(top loading) 14″ x 12″ x 3 1⁄2″ (side loading) |
| Large Flat Rate Box | $22.65 | 70 lbs. | 12 1⁄4″ x 12 1⁄4″ x 6″
|
| APO Large Box | $21.15 | 70 lbs. | 12 1⁄4″ x 12 1⁄4″ x 6″
|
USPS is widely favored for its flat-rate shipping services, making it an excellent choice for businesses that frequently ship small, similarly sized items. Refer to the chart above to determine if your most commonly sold products qualify for these cost-effective shipping rates.
USPS provides specially designed boxes tailored to specific items, such as these DVD boxes. Sold in packs of 25, each box measures 8 ¾” x 5 9/16” x 7/8”, making them perfectly sized to hold one or two DVDs or CDs. These boxes, along with a wide range of other shipping supplies, can be delivered to your business at no additional charge. To qualify for this perk, you’ll need to use USPS shipping services, but for companies that frequently ship DVDs, especially in multiples to the same customers, these cost-effective boxes can be a game-changer for your bottom line.
UPS
UPS offers a variety of boxes that can be ordered through their stores or online. Many of these boxes are provided free of charge to businesses in need. UPS Express offers a wide range of shipping boxes in various sizes, enabling enterprises to easily select the ideal option to meet their specific shipping needs.
| Box Size | Prices | Maximum Weight | Potential Uses |
| 1-100 in3 (XS) | $8.80 (Ground)
$14.65 (3-Day Select) $17.70 (2nd-Day Air) $25.75 (Next Day Air Saver) |
70 lbs. | Shirts, mugs, glasses, phone accessories, writing implements, small toys |
| 101-250 in3 (S) | $11.50 (Ground)
$17.70 (3-Day Select) $21.10 (2nd-Day Air) 32.75 (Next Day Air Saver) |
70 lbs. | Books, packs of paper, notebooks |
| 251-650 in3 (M) | $13.90 (Ground)
$25.20 (3-Day Select) $27.00 (2nd-Day Air) $36.80 (Next Day Air Saver) |
70 lbs. | Binders, shoes, hats |
| 651-1,050 in3 (L) | $18.40 (Ground)
$33.75 (3-Day Select) $48.15 (2nd-Day Air) $55.15 (Next Day Air Saver) |
70 lbs. | Football, small laptop, large books |
| 1,051-1,728 (XL) | $22.85 (Ground)
$42.40 (3-Day Select) $62.40 (2nd Day Air) $71.40 (Next Day Air Saver) |
70 lbs. | Sports equipment, large laptops, kitchen appliances |
UPS provides fixed-price shipping boxes tailored to your chosen size and delivery timeframe. To make the most of their shipping services, it’s essential to determine in advance which boxes are best suited for the items you’re sending.
UPS offers more than just boxes. They also provide specialized tubes, perfect for mailing blueprints, drawings, or important documents. These tubes come with protective pouches that enable recipients to view the contents. Additionally, UPS offers Paks, corrugated boxes designed to securely wrap large, flat, and sturdy items, ensuring safe and efficient shipping.
One key distinction between UPS and other carriers is that, as a federal organization, UPS allows you to ship custom or DIY boxes as long as they meet its size and weight requirements. In contrast, other carriers typically require the use of their branded packaging to ensure uniformity and to incentivize businesses with the offer of free shipping supplies.
FedEx
FedEx offers a diverse range of box sizes for shipping, catering to various types of merchandise. These boxes are ideal for businesses that sell products in diverse dimensions, such as electronics stores offering a wide range of items, from replacement chargers and computer mice to TVs and gaming systems.
FedEx offers standard box sizes with flat-rate pricing that varies based on the shipping distance. To help you choose the correct FedEx box size, we’ve outlined its dimensions and recommended uses below:
| Box Size | Local Shipping Rate | Regional Shipping Rate | National Shipping Rate |
| FedEx Envelope
(9½” x 12½”) |
$7.50 | $8.00 | $9.75 |
| FedEx Pak
(10¼” x 12¾”, 12″ x 15½”) |
$7.50 | $8.00 | $9.75 |
| FedEx Small Box
(10 7⁄8″ x 1½” x 12 3⁄8″) |
$8.50 | $9.75 | $10.75 |
| FedEx Medium Box
(11 ½” x 2 3/8” x 13 ¼”) |
$10.50 | $12.25 | $14.00 |
| FedEx Large Box
(12 3/8” x 3” x 17 ½”) |
$15.75 | $17.25 | $18.75 |
| FedEx Extra Large Box
(11 7/8” x 10 ¾” x 11”) |
$24.75 | $28.00 | $39.25 |
| FedEx Tube
(6” x 6” x 38”) |
$24.75 | $28.00 | $39.25 |
FedEx also provides specialized boxes tailored for specific items, such as golf bags, instruments, and laptops. With dozens of options available, these boxes are ideal for businesses handling uniquely sized or shaped products. They are especially beneficial for eCommerce stores offering a diverse range of items, helping to streamline packaging and shipping needs.
Comparing Box Sizes Across Carriers: USPS vs. UPS vs. FedEx
When it comes to shipping products, choosing the right box size is crucial. Not only does it impact the cost of shipping, but it can also affect the safety and security of your items during transit.
There are various carriers available for businesses to choose from, with some of the most popular being USPS, UPS, and FedEx. Each airline offers a range of box sizes to accommodate different types of shipments.
For small businesses seeking to reduce shipping costs, USPS may be the best option due to its flat-rate boxes. These boxes enable you to ship items weighing up to 70 pounds at a predetermined price, regardless of the distance. This can be particularly beneficial for heavy or bulky items that would typically incur higher shipping costs with other carriers. UPS and FedEx also offer flat-rate options, but they are limited to specific box sizes and weight limits.
Another factor for businesses to consider when selecting a shipping carrier is the level of tracking and insurance it provides. The USPS offers basic tracking for all domestic shipments, while UPS and FedEx provide more detailed tracking options, including real-time updates and delivery confirmation. Additionally, UPS and FedEx offer higher insurance coverage for valuable or fragile items compared to USPS.
Custom and Specialty Box Sizes: When Standard Doesn’t Fit
In some cases, standard box sizes and weight limits may not be enough for specific businesses or products. This is where carriers like UPS and FedEx stand out, as they offer custom and specialty box options to meet the particular needs of their customers.
For example, UPS offers a “custom packaging” service, allowing them to create unique-sized boxes at UPS for your shipment. This is especially beneficial for businesses that have irregularly shaped or oversized items that cannot fit in standard boxes.
On the other hand, FedEx offers a range of specialty boxes, including temperature-controlled packaging for perishable items, wardrobe boxes for clothing shipments, and wine shippers for delicate bottles. These options provide peace of mind for businesses shipping fragile or sensitive items.
Optimizing Shipping Costs with the Right Box Selection
Selecting the correct box not only ensures the safety of your shipment but also helps optimize shipping costs. By choosing a box that closely fits your items, you can avoid unnecessary filler materials and reduce the overall weight and size of your shipment.
Additionally, both USPS and FedEx offer flat-rate options for specific box sizes. This means that regardless of the package’s weight or destination, you will pay a flat rate for the box. This can be advantageous for businesses shipping heavy items or multiple items in one box. It also provides a predictable cost for budgeting purposes.
Another important factor to consider when selecting shipping boxes is the materials they are made of. While traditional cardboard boxes are the most common choice, environmentally friendly options are now available, including those made from recycled or biodegradable materials.
How a 3PL Can Help with Fulfillment Costs
3PL services streamline your fulfillment process by leveraging their expertise to select the ideal box sizes tailored to your business needs. Examples of third-party fulfillment providers include:
- Analyzing carrier options to provide your business with the most cost-effective shipping solutions.
- Bargaining with carriers to secure the most competitive DIM shipping rates.
- Optimizing packaging by consolidating products into fewer boxes and selecting the most cost-efficient box types for your items.
- Streamlining weight and size by not only choosing the correct box sizes but also using fillers that minimize both weight and costs.
- Splitting orders across multiple boxes to maximize cost efficiency can significantly influence how carriers calculate the DIM weight of your products.
A 3PL provider like eWorld Fulfillment empowers eCommerce businesses to delight their customers by negotiating better shipping rates and leveraging their expertise to pack items most cost-effectively and efficiently. With numerous options available for shipping materials, the right third-party fulfillment partner can streamline this complex process while unlocking significant cost savings for your e-commerce business.
Ready to Streamline Your Shipping? Partner with eWorld Fulfillment
Are you tired of juggling multiple shipping carriers and trying to negotiate the best rates for your eCommerce business? Do you want to reduce your shipping costs without sacrificing quality or delivery times? Look no further than eWorld Fulfillment – the ultimate solution for all your shipping needs.
At eWorld Fulfillment, we recognize that shipping is a vital component of any e-commerce business. That’s why we have dedicated our efforts to delivering top-notch fulfillment services tailored to meet the unique requirements of each client. Our team of specialists works tirelessly to ensure that your products are packed efficiently and shipped at the most affordable rates possible.
Contact us today and let us help you take your eCommerce business to the next level. We offer a wide range of services, including inventory management, order processing, and real-time shipping updates. With our state-of-the-art technology and strategic partnerships with top carriers, including USPS, UPS, and FedEx, we guarantee fast and reliable shipping for your customers.